Over the years, different types of lasers have established themselves thanks to their versatility. Apart from technical differences in construction, the particularity of each laser lies in the propagation medium used to emit energy and the resulting wavelength.

The most common are gas lasers (such as the CO2 laser), semiconductor lasers, fibre optic lasers and solid-state lasers. Depending on the medium used, the laser generates a beam at a different wavelength. The lasers manufactured so far cover the entire electromagnetic spectrum.

Why the laser wavelength is key

The wavelength is crucial in determining the possible uses of a laser. From it depends the kind of interactions between the laser and the material. Each material responds differently to a certain wavelength. Some materials, like acrylic, can absorb in the near IR or be transparent in the far IR. The optimum balance is achieved when most of the energy generated by the laser is absorbed by the material, allowing efficient processing.

Based on what we have said, it is impossible to establish an optimal wavelength. The choice depends on the characteristics of the material to be processed.

However, it is possible to give general indications. It has been demonstrated that some lasers have a wavelength which makes them suitable for a wide range of applications.

The wavelength of CO2 laser

The CO2 laser in particular has a wavelength of 10.6 micrometres, which is in the far-infrared region. This length is absorbed very well by all materials containing carbon. Wood, paper, plastic polymers, organic materials, natural and synthetic fabrics respond perfectly to CO2 laser radiation.

What’s your need?

Certainly, of all lasers, the carbon dioxide laser has proved to have the greatest versatility and has therefore established itself as the main choice for the laser processing of materials. Contact us for more information!

Laser kiss cutting (or kiss die cut) consists in removing the superficial portion of a sheet of material according to a specific cutting path. Unlike normal laser cutting, laser kiss cutting does not go through all the material but remains on the surface layer. Due to this characteristic, kiss cutting is mainly used in the paper converting and textile industries.

Laser kiss cutting is used when the superficial layer of a material made up of two attached sheets must be cut.

Laser die cutting of labels is an example of one of the most common applications of kiss cutting. The laser cuts out the surface layer into the shape of the adhesive to facilitate its removal from the support layer.

Laser kiss cutting can also be applied to the field of fabric decoration.

Kiss cutting for digital converting

Digital converting or laser converting is used to perform paper converting processes that would be difficult or impossible to achieve with conventional mechanical methods.

Laser kiss cutting is a typical digital converting application that, as previously mentioned, is particularly used in the production of adhesive labels.

This technique makes production particularly efficient and advantageous, since the costs and time required to set up the machine are eliminated.

In this sector, the materials most used for kiss cutting are:

• paper and derivatives
• polyester
• plastic film
• adhesive tape

Kiss cutting for the textile sector

In the textile industry, laser kiss cutting and laser cutting are used to decorate both semi-finished fabrics and finished garments. In the latter case, laser kiss cutting is very useful for creating personalized decorations.

This technique makes it possible to create different effects such as embroideries, appliqués and labels of various types.

Generally speaking, in this family of applications, two pieces of fabric are sewn together.

Laser kiss cutting then cuts out a shape on the surface layer of the fabric. The upper shape is then removed making the underlying drawing visible.

Kiss cutting is applied mainly on the following textile materials:

• synthetic fabrics in general, in particular polyester and polyethylene
• natural fabrics, especially cotton

The advantages of laser kiss cutting

The kiss cutting technique is not a modern discovery related to laser technology but dates back to traditional printing techniques.

Compared to these mechanical cutting methods based on blades and dies, laser kiss cutting offers several advantages:

• the cutting path can be very complex, making detailed and precise cuts
• the possibilities for customization are innumerable even within the same production cycle
• it can be performed on a large number of materials without interrupting production
• cutting tools don’t get worn during production which therefore eliminates the need for maintenance
• speed, productivity and processing quality are at their maximum
• edges are clean cut and defined and do not need further finishing

The industries of laser kiss cutting

As we have seen, laser kiss cutting is mainly used in the digital converting and textile decoration sectors.

Which laser systems are suitable for laser kiss cutting

Each laser kiss cutting application must be tailor made for each customer’s needs. In the label industry, a system consisting of a CO₂ laser source and a scanning head is generally used.

The laser source

For the manufacturing of labels, high power isn’t necessary: most applications can be done with a laser source below 500W.

Keep in mind though that the power is directly proportional to the production speed. It is therefore sometimes necessary to resort to higher power because of production needs.

A small clarification on the source’s wavelength: El.En. has developed a CO₂ laser source specially designed for label manufacturing, the RF333P, with a wavelength of 10.2 micrometers.

This wavelength is ideal for polypropylene (PP), of which is made the surface layer of most labels is made. This source is a variant of the Self Refilling series, which are the most suitable for paper labels.

The scanning heads

The scanning head always works in combination with a laser source. Its function is to move the laser beam on the work surface and keep it focused. To do this work the source uses mirrors mounted on galvo motors and a focusing lens on the Z axis.

El.En. produced a scanning head for CO₂ lasers called GioScan. The machine is available in two models:

• GioScan 1735, capable of operating on a surface between 135×135 mm and 800×800 mm
• GioScan 1770HR, capable of operating on a maximum area of ​​2300×2300 mm

A laser system for each laser application

Laser kiss cutting applications are numerous and ultimately depend on the material and production needs.

The advantage of laser technology is that it is possible to create custom applications.

For over 35 years El.En. has produced laser systems for industrial applications.

If you have a production idea in mind that requires laser kiss cutting, send us a message and our team at El.En. will find a laser solution that best suits your needs.

Wood, paper, cardboard, plastic, PMMA. And also rubber, leather, metals, and ceramics: CO2 lasers can cut a great number of materials. For this reason, CO2 lasers have become the most widely diffused laser technology for laser material processing.

However, despite the wide use of the CO2 laser we receive a lot of questions on possible appications that can all be summed up by what materials can be cut by CO2 laser? In this article we answer to this question with a simple list of materials that can be easily cut with CO2 lasers (the links take to articles that examine each topic in depth): 

• Wood based materials
• Paper based materials
• Acrylic (PMMA) and other plastic polymers
• Leather and faux leather
• Natural and synthetic fabric
• Biologic materialAll industrial sectors that need to process these materials can thus use the laser CO2 for a faster, smoother, and more precise cutting process.

Fields of application

To go into the details, the following list displays the main applications of CO2 laser cutting, ordered by industry:

• Papermaking industry
  • Cutting cardboard boxes
  • Cutting paper and cardboard
  • Stencil cut
  • Decorations

• Woodworking industry
  • The cutting of any kind, and thickness, of wood, especially Plywood and MDF
  • Inlay fine wood
  • Engravings of any kind

• Engravings and inlays
  • Laser engraving and cutting methacrylate
  • Laser engraving and cutting leather goods
  • Laser engraving name and number plates
  • Laser engraving and cutting textiles
  • Laser engraving electronic components
  • Laser engraving anodized aluminum and varnished metals. N.B.: the CO2 laser usually doesn’t cut metal but can label or mark them indelibly.
  • Engraving of glass, marble, and stones
  • Inlays on ivory

• Creation and Customization
  • Laser cutting hollow punches
  • Laser cutting for architectural models
  • Laser cutting plastic, cardboard, or wooden displays.
  • Contour and cut labels
  • Personalizing gadgets
  • Personalizing buttons
  • Material machining for model making

The list above is just a short list of the many different materials that can be processed by the CO2 lasers: there are lots of other materials that can be cut with the CO2 laser. Research on the applications of the CO2 laser is still an ongoing process, of which experimentation plays an important role: only experimentation provides us with certainty about the possible applications. For this reason we invite you to contact us whereby the material you want to work is not presented in the above list. Together we will find you the solution that fits your needs!

The CO2 laser has been on the market for many decades. Over the years it has proven to be a sturdy tool, capable of providing thousands of hours of processing without having to be serviced or replaced.

Unlike for mechanical production equipment, one of the biggest advantages of laser processing is low maintenance.

Mechanical tools operate by contact between parts and rely on moving mechanisms. The friction generated during machine operation makes wear and tear on this production equipment a pressing problem. Periodically, production has to be stopped in order to carry out the necessary maintenance operations, which increases the costs of operation and processing. The die sector is but one example of an industrial process that suffers from this problem. In this type of application, the dies have to be replaced periodically to guarantee the quality of the cut.

Laser, on the other hand, is a non-contact process. The entire laser system is based on the production and transmission of electronic pulses and the generation of polarised light beams. There are no moving parts or friction and therefore no direct impact on the lifetime of the laser source.

However, this does not mean that laser sources are maintenance-free. Laser sources also wear out, albeit much more slowly. This is why they need regular maintenance.

In the case of CO2 laser sources, the main problem is the rarefaction of the gas inside the laser tube. Year after year, the gas mixture is normally depleted, resulting in around a 1-2% emitted power decrease per year. This causes a gradual deterioration of the processing and a consequent decrease in efficiency.

The only solution to this problem is to periodically regenerate the laser source. However, this is a costly and time-consuming operation that usually involves stopping the production line, resulting in a negative impact on productivity.

El.En. has created a series of laser sources based on Self-Refilling technology to overcome this very problem. These sources, called Never Ending Power, avoid the regeneration of the source thanks to the use of a cylinder that contains the propagation medium. This cylinder can easily be replaced without causing any delays and guarantees the same process parameters and power over time.

This innovative recharging technology now makes it possible to have a laser source that always functions at maximum power. The laser beam’s quality will consistently remain at its highest level and the lifespan of the laser source will practically be infinite. Contact us for more information!

One of the characteristics of CO2 lasers is that it allows you to carry out processes which were impossible to perform beforehand, because of technical limitations in the past.

The CO2 laser has introduced new possibilities that have been exploited to meet market demands. One of these advantages is, for example, the laser micro perforation of plastic film. This technique has proven to be very useful for the packaging of fresh products before distributing them to mass retailers.

Micro perforated bags with laser for the packaging of fresh products

Laser microperforation is one of the newest methods to create micro holes in the packaging materials of products. To do this, the CO2 laser is used in pulsed mode. Unlike continuous mode, the pulsed mode sends high-intensity light flashes on the packaging material.

Laser micro perforation is particularly important for the packaging industry of fresh products. An increase in the demand of ready to consume fruit and vegetables, distributed via mass retailers, has led to the development of new strategies to ensure product freshness. Controlling storage temperature and modifying the atmospheric conditions within the packaging of products are the two most important factors for the quality of fresh products. The packaging thus has an important role in maintaining the freshness of the product, as it works as a regulator between the interior and exterior environment.

Laser micro perforation allows you to optimize the conservation of these products, through an improvement of the product packaging.

Objective: to improve the breathability of plastic bags

The packaging materials of fresh products in controlled atmosphere are often seen in the form of plastic bags. These bags allow optimal isolation of the products, and seal them perfectly from external contamination of molds or bacteria.

But there is a disadvantage: the breathability of these materials. Plastic film is a material that limits gas transmission with the exterior atmosphere. For a proper preservation of fresh products this is a significant disadvantage, as fresh products are subject to metabolic changes such as breathing, exchanging gases with the exterior atmosphere, and producing gas from chemical processes that take place within the fresh produce.

To improve the shelf life of a product, a continuous gas transmission between the interior and exterior atmosphere of the packaging is required. The levels of oxygen and carbon dioxide, play a big role in the conservation of the product. For this reason plastic bags must be perforated, in order to facilitate a proper gas flow between the internal and external environments. The amount of gas transmission required, however, differs from product to product. For this reason the perforation process must be properly adapted to the product needs. This aspect of adapting the perforation process, however, is difficult to achieve with traditional perforation methods.

Traditional micro perforation processes of plastic bags

Traditionally, the perforation of plastic bags is performed through two types of mechanical processes:

• Heated or unheated needles: the plastic film is perforated by needles applied with or without heat. This process, though inexpensive, is slow. In addition, the holes produced have a larger diameter and can let contaminants, such as bacteria and mold, in. It is therefore not suitable for contaminant-sensitive products.
• Electric discharge: packaging bags can also be perforated by means of electric discharge. The plastic film is passed through a high electrostatic voltage in which sparks are led through the packaging film to create micro holes. This process, even though faster than the previous one, is hard to manage. The hole parameters can not easily be checked. It is therefore unsuitable for those products that require precisely controlled gas transmission.

Laser Micro Perforation: accuracy in the service of the product

The machine that generates the best results in terms of micro perforating bags, turns out to be the CO2 laser. Micro perforation with the CO2 laser makes it possible to control the drilling process very accurately and obtain high quality results.

The CO2 laser is very well absorbed by most polymers and thermoplastics. The controlling software makes it possible to set the parameters to obtain holes of the required size and density, that let you create the optimum environment for gas transmission.

Laser cleaning is the process of using lasers to remove dirt, debris or contaminants from the surface of an object. It is a process that lends itself to a variety of industrial and non-industrial applications. From cleaning thermoforming moulds to restoring monuments, there is no area where laser cleaning cannot be successfully applied.

In this article, we explain what the laser cleaning process consists of, the principle on which it is based and why it has an advantage over conventional cleaning methods.

Conventional cleaning methods

In the field of industrial production, the maintenance of production tools is essential, particularly in those areas where the quality of production depends on it. In the plastic thermoforming sector, for example, it is essential to always have clean moulds in order to obtain high quality parts. Rust, dust and material residues are among the most common types of dirt that need to be periodically removed.

However, cleaning operations are very costly in terms of resources. The actual performance depends on the type of maintenance required. But in general we can say that cleaning methods are based on the use of chemical or mechanical methods.

In the first case, cleaning is entrusted to solvents, detergents or other chemical compounds that degrade the material to be removed and facilitate its removal. In the second case, systems such as sandblasting or ultrasonic cleaning are used.

These cleaning methods have major disadvantages. They are very polluting because of their use of chemical products and require operators to take special safety precautions.

In addition, physical contact often causes damage to the workpiece which, in the long run, ends up being damaged by the cleaning operations.

Laser cleaning has established itself precisely because it has the advantage of overcoming the main drawbacks of traditional cleaning methods.

Laser cleaning and its advantages

Laser cleaning consists of irradiating the surface of a material in such a way as to remove the surface layer. The technique is based on ablation. The beam concentrated on the material breaks the molecular bonds of the material that needs to be removed. The material evaporates instantaneously with virtually no residue left behind.

Unlike conventional methods, there are no solvents or other additional chemical substances used in laser cleaning, and since it is a non-contact process, there is no abrasion that could damage the workpiece, as the surface dirt is removed without attacking the underlying material.

It is precisely this protection of the material that makes the laser so attractive. The laser allows you to operate selectively on a given material. The laser only removes materials that are absorbed by its wavelength. In addition, each material has different properties and needs a different amount of energy to be removed. This makes it possible to work on materials very precisely, to calibrate the laser extremely selectively so as not to damage the underlying material.

Flexibility, high controllability of the medium and speed are the characteristics that make laser cleaning an extremely effective tool.

The laser scanning heads are a fundamental component of the galvo systems for laser cutting and marking. These devices deflect the laser beam coming from the source and move it along the X and Y axes according to the operation required.

The components of a galvo head for laser

A scanning head is made of different components.

Galvo mirrors

Mirrors mounted on galvanometric rotary motors deflect the laser beam. These motors transform electrical voltage into angular movement.

The mirrors, mounted perpendicularly on the engines, move the laser beam along the X and Y axes according to the input received from the motor.

The big advantage of these devices is that they can reach a very high acceleration and speed of movement.

The size of the mirror depends on the laser beam. As the diameter and the power of the beam increase so must the diameter of the mirror. The same size in turn influences the acceleration and speed of the engine’s angular movement. The smaller mirrors reach higher accelerations than the larger mirrors.

In the range of El.En.’s products there are galvanometric mirrors for different applications. Find out more about our complete 2-axis CO₂ laser galvanometer mirror line on our website.

Z-linear optics

Galvo mirrors are not the only components of a scanning head. The z-linear lens, which focuses the laser on the work surface, has an important role to play too.

To focus the laser beam and get it to work optimally, the focal length of the lens must vary based on the distance between the scanning head and the point it needs to reach on the surface.

The z-linear lens changes the focal length in real time and maintains the laser beam in focus regardless of its distance from the workpiece.

The control software

The control software makes sure that all the moving parts of the scanning head stay coordinated.

It transforms a vector file (the place where the work to be performed is described), into a path for the laser beam. The control software makes the galvo head and the laser source work together to achieve the desired result.

What processing can be performed with a laser galvo head?

As previously mentioned, the laser galvo heads are mainly used for cutting and laser marking.

Laser galvo cutting

Galvo heads make it possible to reach high processing speeds for cutting applications. Galvo heads are perfect for the processing of thin materials such as paper, cardboard and plastic film.

The head can cut out any shape quickly.

Some of the industries that benefit most from the use of galvanometric motors are the adhesive label sector that use kiss-cutting applications and the packaging industry that uses galvo-laser applications to make products with advanced features.

Galvo laser marking

The main marking applications include the marking of various types of alphanumeric codes, such as barcodes and QR codes, and the engraving of ornamental motifs for decoration.

Laser marking can be performed on different materials such as thermoplastic polymers, wood, fabrics, leather, metals, glass.

In the case of transparent materials it is also possible to perform the impression of three-dimensional figures inside the object.

The advantages of laser galvo heads

Laser applications get many advantages from the use of galvo heads:

• Speed – The galvanometric motors reach very high angular speeds. This means that the laser beam moves over the surface of the workpiece with speeds reaching tens of centimeters per second. Thanks to this the productivity of a laser galvo system is very high.
• Integration – Precisely because of this characteristic, galvo laser systems are suitable for integration into larger production flows. A laser galvo system consisting of a scanning head and a laser source performs best when inserted into automated processes. Furthermore, it is compact enough to be easily added to pre-existing systems, giving it an important upgrade without major changes.
• Quality – The laser galvo systems guarantee high quality and detailed results. In marking applications, the scanning head gives the possibility to create a wide range of effects, including the reproduction of a photograph on a surface.

One device, many tools

Scanning heads are a key tool in laser material processing applications. They transform a single beam of polarized light into an instrument with many applications.

To choose the scanning head that is most compatible with the application you need, request the help of an expert. Get in touch with us: our team at El.En. will be happy to help you find the most suitable laser scanning head for your applications.

Laser labeling of food is a recent innovation that makes it possible to reduce production waste by replacing traditional food labels with laser engraved labels. Laser marking of food is suitable for companies wanting to optimize their production process, saving resources and materials while also decreasing their ecological footprint. The possibilities are endless.

In fact, an increasing number of companies have realized that laser techniques are the key to process innovation. In a recent article we discussed the growing phenomena of natural branding, a process in which traditional food labels are replaced by the laser marking of the skin of food.

Fresh products such as fruits and vegetables can easily be marked through a laser scanning head, a low power CO2 laser source and a software that controls the process. This procedure of laser marking permits us to imprint logos, barcodes, and any type of information on different types of food without affecting their quality. The marking does not affect the organoleptic properties of the food – it is a “friendly process” as it only affects the most superficial layer of the skin of fresh products.

However, fruits and vegetables are not the only types of food that can be marked with the CO2 laser technology. Results have shown that even seasoned and semi-seasoned cheese and hams can be marked.

A case study: machine designed to mark seasoned and semi-seasoned cheese.

These seasoned and semi-seasoned products have always been marked through heat methods. Products are marked with their brand and codes that establishes the batch of production, identify the producer, allow to trace back the origin of the product. The easiest system to mark food is to use a metal to impress a brand by burning the surface of the product.

This traditional method, while being inexpensive, is incredibly slow and inflexible. In order to change the codes to be imprinted, a change in the marking tool is needed.

A more efficient way of imprinting information on food is to use the CO2 laser application. The laser allows to mark the surface of these products faster, with higher precision, and in a more secure way. In comparison to traditional ways of marking food, such as marking through means of heat, laser marking allows us to have an extremely precise process: it provides the possibility to adapt all parameters involved to suit the characteristics of the product to be marked. In this way the process of laser marking becomes the more precise way as it respects the unique characteristics of each product.

A system for marking the dairy products may consist of the following elements:

• Completely washable stainless steel structure
• Conveyer belt
• CO2 laser source
• High performance laser scanning head
• Controlling software

The functioning is semi-automated. The system involves the presence of an operator placing the products to be marked on the conveyer belt. The conveyer belt transports the products to the laser processing space, isolated from the outside with doors that can be opened for inspection and sanitation reasons. Here the laser scanning head, controlled by a software, guides the laser beam on the surface of the product, performing the marking within seconds. In a few minutes only, the operator is able to perform the same operation dozens of times.

The advantage of such a system is its flexibility. First of all, the machine is designed to be modular: each module can be replicated and adapted to the needs of the manufacturer. For example, you can install different laser sources for different applications.

Furthermore, the system allows you to change the information you want to mark very quickly. You just have to modify the parameters inserted in the control software to perform a different process.

Laser cleaning is one of laser’s many applications. The process is based on laser ablation, i.e. the removal of a portion of material from a surface. Ablation is at the basis of all common laser processes: cutting, drilling, engraving, marking.

While the purpose of these processes is to create cuts, holes or marks in the material, the aim of laser cleaning is to remove dirt particles from a given surface.

Laser cleaning of industrial moulds

The production process of thermoplastics is an example of an industrial laser cleaning application. The main production method for these materials is moulding. At the end of the production process, the moulds need to be restored to their original state. This step is crucial because the quality of the final part depends on it. The presence of material residues, or other debris, affects the final quality of the parts.

Traditionally, the cleaning process is carried out using one of three techniques: dry ice blasting, ultrasonic cleaning or manual cleaning. Each has both advantages and disadvantages.

Dry ice cleaning consists of directing a high pressure jet of dry ice onto the mould. The ice penetrates the mould cavities and removes residues. The operation is carried out by an operator who directs the jet onto the areas that need to be cleaned. The advantage of this technique is that it can be used directly in the production line. However, it is not an environmentally friendly method since it requires the use of large quantities of dry ice.

For ultrasonic cleaning, the mould is placed in special ultrasonic cleaning machines. In practice, this involves disassembling the part and immersing it in special tanks filled with solvent and water. In addition to the need to disassemble the mould, this method has the disadvantage of using polluting chemicals.

Manual cleaning consists of cleaning the moulds using a solvent and manual force. It is a slow and inefficient method.

Laser cleaning overcomes these disadvantages.

Firstly, it can be performed selectively: the laser only acts on materials that are compatible with its wavelength. Laser cleaning can therefore be used in sensitive applications where abrasion-based procedures such as sandblasting would be too invasive.

The absence of waste also makes it an environmentally friendly technique. Laser cleaning doesn’t use solvents or other chemicals, doesn’t produce any waste and also doesn’t consume water or other resources. It is a thermodynamically efficient process. The laser vaporises the material by sublimation which makes it an environmentally friendly process.

Finally, laser cleaning is extremely precise. The process is completely digitally controlled which makes it possible to work on extremely small surfaces or follow extremely complex cleaning patterns. Unlike with traditional methods, it can clean hard-to-reach spaces and uneven surfaces.

A system tailored to your application

Laser cleaning is a versatile application. It is efficient, adaptable, precise and most importantly, ecological. El.En. is the ideal partner to create a tailor-made application for your production process. Contact us and we will be happy to help you find the best solution for your needs!